Resin panel spacer block for energy absorption, load support, and gap prevention

ABSTRACT

A spacer for vehicle panels can be shaped such that it absorbs a substantial portion of a first load, the first load applied in a first direction substantially perpendicular to the exterior panel; controllably deforms along a second direction when a second load is applied substantially along the second direction; wherein the second direction is other than the first direction. The spacer need not deform along the second direction when the first load is applied. The spacer can have a shaped member having a channel extending through the spacer perpendicular from the exterior panel, such that the spacer can controllably deform along a width of the channel.

TECHNICAL FIELD

The present disclosure relates generally to panel spacers compositepanel systems structurally reinforced with panel spacers.

DESCRIPTION OF RELATED ART

Composite panels, such as resin composite exterior panels are common invehicles. For example, resin composite is lightweight and allows forstyling flexibility for design of a variety of vehicle body shapes.However, during collisions, resin panels may fracture and break awayleaving gaping holes along panel seams, weak areas, or break points invehicle panels such that lightweight panels may not provide adequateprotection of the passenger compartment from objects entering or leavingthe cabin (i.e. when the vehicle panel is a door) during a collision.

BRIEF SUMMARY OF THE DISCLOSURE

Embodiments may provide improved resin composite panels. The presentdisclosure provides systems and methods for improved resin panels withan easy to manufacture and/or assemble spacer block for energyabsorption, load support, and gap prevention. Embodiments of the presentdisclosure provide both strength and durability, but also deformabilityand flexibility, to a lightweight, yet brittle vehicle exterior panel.

Embodiments may provide a spacer for vehicle paneling.

Spacer can include a top portion. Top portion can include an exteriorpanel coupling surface. Exterior panel coupling surface can beconfigured to couple to an exterior panel of a vehicle.

In embodiments, spacer can include a shaped member extending from topportion to a bottom portion. Shaped member can include one or morechannel extending through the spacer. The channel can extend from theexterior panel coupling surface.

In embodiments, the shaped member can at least partially circumscribe avertical aperture extending through the shaped member. The shaped membercan at least partially circumscribe a vertical aperture extending fromexterior panel coupling surface to bottom portion.

In embodiments, the shaped member can be configured to absorb asubstantial portion of a first load applied in a first direction. Thefirst direction can be perpendicular to the coupling surface (orsubstantially perpendicular to the coupling surface).

The channel can be configured to allow a controlled deformation. Thechannel can allow for a controlled deformation (e.g. of the spacerand/or the spaced member). The channel can allow for a controlleddeformation when the first or a second load (or a component thereof) isapplied substantially along a direction along a width of the channel.

In embodiments, the channel can have a vertex closer to a geometriccenter of the spacer than a geometric exterior of the spacer.

In embodiments, the channel can extend through the entire shaped member.

In embodiments, the spacer can further include a tether coupled to theshaped member on a first side of the channel. In embodiments, the tethercan be coupled to another point of the shaped member of a side of thechannel other than the first side.

In embodiments, shaped member can expand upon an impact. Tether can beconfigured to delay an expansion of the spacer block upon an impact.

In embodiments, the spacer for vehicle paneling can be made of durableresin. The spacer can have a higher tensile strength in the firstdirection than the direction along the width of the channel.

In embodiments, the spacer for vehicle paneling can be configured forinsertion in a body of a vehicle. In embodiments, the spacer for vehiclepaneling can be configured for insertion between an exterior panel, suchas an exterior body panel, and a geometric center of the vehicle.

A composite panel system can include spacer for vehicle paneling asdescribed herein.

In embodiments of composite panel systems, the composite panel systemcan include an exterior panel. The composite panel system can furtherinclude a first spacer. The first spacer can be proximal to the exteriorpanel.

In embodiments, the first spacer can be shaped and/or otherwiseconfigured as spacer described herein. The first spacer can beconfigured to absorb at least a portion of a first load. First load (orcomponent thereof) can be applied in a first direction substantiallyperpendicular (or perpendicular) to the exterior panel.

In embodiments, first spacer can be configured to controllably deformalong a second direction when a second load is applied substantiallyalong the second direction. The second direction can be other than thefirst direction. In embodiments, the first spacer does not deform alongthe second direction when the first load is applied.

In embodiments, the first spacer can include a shaped member. The shapedmember can include one or more channels. One or more channels can extendsubstantially perpendicular to the exterior panel. One or more channelscan extend from the exterior panel. One or more channels can extend atleast partially though the first spacer.

In embodiments, the one or more channel can be configured to allow acontrolled deformation when the first load is applied substantiallyalong the second direction. In embodiments, the one or more channel canbe configured to allow a controlled deformation when the second load isapplied substantially along the second direction.

Embodiments of composite panel systems can include a second spacer. Thesecond spacer can be positioned on the same side of exterior panel asthe first spacer.

The second spacer can further include a second spacer shaped member.Second spacer shaped member can include one or more channels. The one ormore channels of the second spacer shaped member can extend from theexterior panel. The one or more channels of the second spacer shapedmember can extend at least partially though to the second spacer.

In embodiments, first spacer and second spacer can be arranged in ahoneycomb pattern. In embodiments, first spacer and second spacer can bearranged such that first spacer shaped member and second spacer shapedmember couple at an angle. In embodiments, the angle is 120 degrees.

In embodiments of composite panel system, the composite panel system caninclude a tether coupled to the shaped member (i.e. the first shapedmember or the second shaped member). Tether can be coupled to one otherpoint of that spacer.

In embodiments, shaped member (i.e. the first shaped member or thesecond shaped member) can be configured to expand upon an impact. Tethercan be configured to delay an expansion of the spacer block upon animpact.

Composite panel systems can further include an inner panel. Inner panelcan be on the other side of the first spacer (and/or second spacer) thanthe exterior panel. In embodiments, the first spacer (and/or the secondspacer) is fastened to the inner panel. In embodiments, first spacer(and/or second spacer) is fastened to the exterior panel.

In embodiments, first spacer (and/or second spacer) is fastened to theexterior panel such that in the event of a fracture at the exteriorpanel, the exterior panel remains seamed together. In embodiments, firstspacer (and/or second spacer) is fastened to the interior panel suchthat in the event of a fracture at the exterior panel, the exteriorpanel remains seamed together.

In embodiments, shaped member (i.e. first shaped member and/or secondshaped member) can include a living hinge. The living hinge may allowfor the shaped member to controllably deform along the second direction.

In embodiments, first spacer (and/or second spacer) can be made ofdurable resin. Durable resin can have a higher tensile strength in thefirst direction than in the second direction. First spacer (and/orsecond spacer) can have a higher tensile strength in the first directionthan in the second direction.

In embodiments, composite panel system can be configured for insertionin a vehicle. In embodiments, the exterior panel can be configured as aportion of a body of the vehicle. In embodiments the composite panelsystem can be configured for insertion in vehicle such that the exteriorpanel can be a portion of a body of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure, in accordance with one or more variousembodiments, is described in detail with reference to the followingfigures. The figures are provided for purposes of illustration only andmerely depict typical or example embodiments.

FIG. 1A shows a top plan view of spacer block having controlleddeformation support channels according to aspects of the presentdisclosure.

FIG. 1B shows a top plan view of another spacer block having channelsaccording to aspects of the present disclosure.

FIG. 1C shows a top plan view of yet another spacer block havingchannels according to aspects of the present disclosure.

FIG. 2A shows a side view of a composite panel system including a spacerblock according to aspects of the present the disclosure.

FIG. 2B shows a side view of a composite panel system including twoparallel spacer blocks according to aspects of the present disclosure.

FIG. 3 shows a top plan view of a honeycomb spacer block pattern of twocomponent spacer blocks, according to aspects of the present disclosure.

FIG. 4A shows a top plan view of another honeycomb spacer block patternaccording to aspects of the present disclosure.

FIG. 4B shows a top plan view of yet another honeycomb spacer blockpattern, according to aspects of the present disclosure.

The figures are not exhaustive and do not limit the present disclosureto the precise form disclosed.

DETAILED DESCRIPTION

Embodiments of the present technology provide one or more spacer blockspositioned behind and coupled to the inner surface of exterior panels.As described herein, exterior panels can form external surfaces ofcomponents of a body of vehicles, such as passenger doors, quarterpanels, bumpers, luggage compartment doors, wheel wells, and/or enginehoods of a vehicle. As described herein, vehicles can be flying,submersible, boats, roadway, off-road, passenger, truck, trolley, train,aerospace, or other vehicles. These exterior panels may be likely tosustain impact forces and lateral damage in the event of a collision.The present disclosure provides a variety of design features such thatthe loads acting on the panel are transferred directly to the spacerblock. The face of the spacer block may provide low compression and highdurability. The walls of the spacer block can be designed with a varietyof intricate features.

FIG. 1A shows a first embodiment of a spacer block 100 in top plan view.Spacer block 100 may be made of a metal such as aluminum. Spacer block100 may be made of a durable resin. Spacer block 100 may have a highertensile strength along one plane or axis (e.g. a plane or axis into thepage in top plan view of FIG. 1A) while providing flexibility andductility along another plane or axis (e.g. along the plane of the paperor parallel thereto in the top plan view of FIG. 1A). The spacer block100 may have a higher stiffness, or modulus of elasticity in a firstdirection, than in a second direction.

Spacer block 100 can have a top surface 103. Top surface 103 can beconfigured to adhere to and/or conform to an exterior panel (not shown).The bottom surface (not shown) can be configured to adhere to aninterior panel or other structural component of the vehicle.

The spacer block 100 can have at least one lateral side 105. The lateralsides 105 can meet to form a substantially polygonal shape. The lateralsides 105 can be substantially straight (e.g. see sides 105 a, 105 b),but can also have curved features, depressions and/or overhangs. Thelateral sides 105 can be substantially uniform in thickness, or be nonuniform. The spacer block 100 can be prismatic in shape (e.g. triangularprism, rectangular prism, hexagonal prism, etc.). The prismatic shapemay be right, oblique, and/or truncated (e.g. non-parallel top 103 andbottom surfaces).

Lateral sides 105 can provide a rigid support along a planeperpendicular to the top surface 103 to provide rigid support againstloads applied to panel(s) adjacent to the top surface 103. The spacerblock 100 can have high strength, stiffness, and/or elastic modulus,along that plane perpendicular to the top surface 103. The spacer block100 may be configured to absorb a substantial portion of a first loadapplied in first direction substantially perpendicular to the exteriorpanel coupled to the spacer block 100. The spacer block 100 may notsubstantially deform in any direction when that load is applied.

The lateral sides can also include various design features, for example,bending seams, channels, expansion points, and crush zones wherepredictable results from impact forces are mitigated. These impactforces may be along planes other than the plane perpendicular to the topsurface 103.

At least one shaped member of the spacer block 100, such as a corrugatedlateral side 105 c, can include bending seams, flutes, expansion points,crush zones, and/or corrugated bends. In embodiments there is at leastone corrugated channel, including even or odd number of channels in thecorrugated lateral side 105 c. Channel(s) in one or more of the lateralsides (e.g. corrugated lateral side 105 c) can allow for a controlleddeformation when a load is applied substantially along a direction alonga width of the channel. Such controlled deformation support channels(s)however, can allow for rigidity and/or support when a load is appliedalong a length of the channel. Channels as described herein, can beformed by rolling and/or stamping.

Each channel can have one or more vertex 106 which is off center from acenter line of the lateral side 105 c. The vertex 106 can be the same,or differently shaped for each channel in the corrugated lateral side105 c. In embodiments, the channel can have 1 mm to 50 cm base size(e.g. a channel width). In embodiments, the channels can have 1 mm to100 cm of spacing between channels. In embodiments, the channels, whenthe spacer is viewed in top plan, can have bends which are “S” shaped.In embodiments, the vertex 106 is substantially plateau shaped,substantially angular, bell shaped, and/or substantially curved. Thevertex 106 can be internal facing (towards a geometric center of thespacer block, such that the concave portion of the channel is externalfacing), or external facing. The vertices 106 can all be facing the samedirection, or be facing different directions. External facing bends whenviewed in can be more than internal facing bends. The corrugated bendscan be facing internal or external to the spacer block 100. For example,in the figure, the bends are facing external to a geometric center ofthe spacer block 100. In some embodiments, the bends can form a waveand/or sinusoidal pattern with a first portion above a centerline of thelateral side, and a second portion below the same centerline of thelateral side. The first portion can be substantially equal to the secondportion.

FIG. 1B shows another embodiment of a spacer block 100 b, havinginternal facing vertices 106 in the corrugated portion of a corrugatedlateral side 105 d. As shown, the corrugated bends can be facinginternal to the spacer block. Controlling the direction of the vertices,and/or the combination of the directions used, may allow for controlleddeformation of the spacer block 100.

FIG. 1C shows a top plan view of another embodiment of a spacer block100 c. The spacer block 100 c can have a generally triangular prismshape, with three lateral sides together defining one or more verticalaperture 110. Vertical aperture 110 may be filling in with lightweightmaterial, such as insulation, and/or other vehicle components. At leastone of the lateral sides 105 e can have a corrugated portion with one ormore bends. Spacing between the bends of the corrugated portion of thelateral side 105 e can be uniform or non-uniform.

The spacer block 100 can have one or more cross beams 150 for furthersupport, (the spacer block 100 can thus have more than one verticalaperture 110). The cross beam 150 can span from one of the lateral sidesto another. The cross beams 150 can be coplanar with the top surface103. Alternatively, the cross beam 150 can be only a portion of athickness of spacer block 100. The one or more cross beams 150 may berigid and/or made from the same or different material than the rest ofthe spacer block 100. One or more cross beam 155 can have a corrugatedpattern, and or contain a living hinge or break seam. The cross beam150,155 may be used to prevent buckling of at least one of the lateralsides 105, and/or add flexibility, rigidity and/or stiffness in aspecific direction. The cross beam 150 may have a cross hatched,honeycomb, or other pattern.

Other designed features may include living hinges and/or break seamsdesigned to provide adequate coverage and structural support, especiallyin the event of a panel fracture. The living hinge and/or the break seammay allow for a controlled deformation. For example, the living hingeand/or break seam may be rigid if an impact force is of a specificmagnitude and/or direction is applied, and controllably deform (e.g. theliving hinge collapsing) if the impact force has a higher magnitude,and/or different direction. The living hinges and/or break seams can bepositioned at one or more of the lateral sides, and/or at a cross beam150.

Other design features may include one or more tether 160 that may delayan expansion and/or compression of the spacer block 100 (or portionthereof) until an impact threshold is exceeded. The tether 160 can beconfigured to delay an expansion of the spacer block upon an impact. Thetether 160 may be coupled between two points of the spacer block 100,such as between two lateral sides 105. The tether can be between twopoints of the corrugated lateral side 105, between the inner panel theexterior panel, between a point of the spacer block and at least onepoint of the inner panel, and/or between a point of the spacer block 100and at least one point of the exterior panel. The tether 160 may havetwo or more attachment points. Tether(s) 160 may be braided stainlesssteel cable, stainless steel tubing, composite, plastic, rope, bungee,or wide webbing material. Tethers may be configured to snap or break ata specific impact threshold. One or more tethers may be used. Tethersmay be configured as expansion and/or compression springs, and/orbungee.

Further, metal, fiber, and/or resin crash zones, and/or crumple zonesmay be designed in an expanded foam, honeycomb, and/or an accordionconfiguration in areas where energy absorption may be more desirable(e.g., front or rear bumpers). For example, an outer surface of thespacer block may be supplemented with a crumple zone.

As shown in FIG. 1A-1C, a spacer block 100 can include lateral sides 105in a corrugated configuration (e.g. with depressed or recessed channels)to prevent any lateral forces acting on an exterior panel from crackingand opening a large gap in the exterior panel, which would normallyoccur in the absence of the spacer block (for example, if the exteriorpanel were made of resin). For instance, the spacer block 100 can absorbthe impact forces acting directly on the top surface 103 of the block(e.g., a top flat surface of the spacer block) while any side load thatwould normally crack and stretch the exterior panel (e.g. if it weremade of resin) to form a gap would be prevented. Side loads that wouldotherwise cause cracks of gaps in the exterior panel would be preventedthrough designed response of the lateral sides of the spacer block 100(e.g. elastic response). The lateral sides can stretch and straightenalong the corrugated section to provide an extended coverage area (i.e.the coverage area between the exterior panel and the spacer block). Thisalso has the effect of dampening the impact as the side wall stretches(e.g. creating resistance similar to a bungee cord). In other words, thespacer block can act as a shield along one axis while also acting as anet along another axis. The unique support to exterior panels providedby the improved spacers described herein can provide both strength andflexibility to a brittle but lightweight exterior vehicle panel.

The lateral sides of the spacer block 100 can define one or morevertical aperture(s) 110. The one or more vertical aperture 110 may gothrough at least a portion of the spacer block 100 from the top surface103 and at least partially through the spacer block 100. Lateral sidesof the spacer block can absorb a substantial portion of a first loadapplied in a first direction perpendicular to the top surface 103.

In one example embodiment, a top surface 103 may be coupled to anexterior panel shaped as a side of a vehicle. If there is an impact atthe door, a load may transfer through the spacer block 100 such that theimpact force acting on the door is absorbed by the spacer block 100. Ifthere is an impact at a side quarter panel adjacent to the door exteriorpanel, this may otherwise create cracks and/or gaps at the exteriorpanel. The design of the spacer block 100 may provide flexibility and/orductility to mitigate such cracks, gaps, and/or other damage to theexterior panel.

The shape and target deformation (controlled deformation) may varydepending on the design of the exterior panel and the materials used.For instance, aluminum, steel or other metal materials (or non-metallicmaterials) may be used as a spacer block 100 in areas where extensivecoverage and travel is desired. However, a lightweight resin block mayalso be used where weight is a concern. Spacer blocks as describedherein can be formed of metal, composites, and/or plastics. For example,the spacer block can be anodized aluminum.

FIG. 2A shows a side view of a composite panel system 200 including aspacer block 202, internal panel 205, and/or external panel 210. Spacerblock 202 can be either of the configurations described herein, e.g.spacer block 100 of FIGS. 1A-C. For example, spacer block 100 of FIG. 1Acan be a top plan view taken across a cross section CS2 of spacer block202. The spacer block 202 can be between the internal panel 205 and theexternal panel 210. In other embodiments, spacer block 202 is positionedbetween internal components of a vehicle, such as structural components,and the external panel 210. Spacer block 202 can be coupled (e.g. bytieing, fastening, welding, gluing, or otherwise attaching) to theinternal panel 205 and/or external panel 210. Spacer block 202 can haveadhesive and/or fastener(s) at least partially between the spacer andthe interior panel and/or between the spacer 202 and the external panel210. The adhesive and/or fastener can be configured to couple the spacerblock 202 to the panels 205, 210. Because the spacer block 202 isfastened to the external panels 210 in select areas, and because of theconfiguration of the vertical sides of the spacer 202 (e.g. thecorrugated portion) the strength and elasticity provided by the spacer202 would act as an adhesive to seam the external panel 210 togethereven in the event a fracture does occur. This is especially apparent inbrittle, composite external panel 210, e.g. with a resin external panel210.

One or more horizontal aperture(s) 215 can go at least partially throughthe entire spacer block 202. The one or more horizontal aperture(s) goat least partially through the lateral sides (105) of the spacer block202. The horizontal aperture(s) 215 can allow for spacer block withreduced weight, yet controlled rigidity and/or flexibility.

The spacer block 202 can have one or more channels 230 going at leastpartially, from the external panel 210 to the interior panel 205. Thechannels 230 in the one or more channels 230 can be equidistant fromtheir adjacent channel(s) 230, and/or have different distances betweenchannels 230. The channels 230 in the one or more channels 230 can havethe same or different widths. Each channel in the one or more channels230 can have a channel width that is constant across a length of thatchannel, or that varies along the length of the channel. The channels230 can be extended from the external panel 210 and/or interior panel205. The channels 230 can be as previously described with reference tocorrugated vertical side(s) 105 c, 105 d, 105 e of FIG. 1A-1C, (i.e.having bent shape in top plan view of the spacer block 202, where thevertex (e.g. vertex 106) is a midline of one of the channels 230). Thechannel can extend through the spacer block 202 perpendicular from theexternal panel 210, such that the spacer block 202 can controllablydeform along a width of the channel(s) 230.

One or more spacer blocks as described herein may work collectively tofurther enhance the strength or absorption qualities by a factor of n.The spacer block may include one or more component spacer blocks, two ormore component spacer blocks, three or more component spacer blocks,etc. Component spacer blocks of the spacer block may be the same (e.g.same size, shape, material, configuration, and/or other features), orthey can be different. Component spacer blocks may be spacer blocks asdescribed herein. Adding more than one spacer block in series and/or inparallel (i.e. from an internal panel 205 to an external panel 210) mayfurther customize and tune the amount of support, resistance,flexibility, strength, and/or coverage desired across a wide range ofapplications. The multiple component spacers can meet with at least onegap, and/or with one or more material between them (such as adhesive,insulation, and/or resin).

FIG. 2B. shows a side view of a series composite panel system 260 havingtwo component spacer blocks 202 positioned consecutively between theinternal panel 205 and an external panel 210. Two or more componentspacer blocks 202 may be stacked to provide twice the compression powerin areas of high impact (e.g., side vehicle impact zones) or anticipatedlarge loads (e.g., truck bed or roof luggage racks). The componentspacer blocks 202 may be selectively fastened, glued, welded, orattached to each other, or otherwise coupled to each other. Thecomponent spacer blocks 202 may be the same, or different, e.g. withdifferent horizontal apertures, vertical apertures, and/or otherfeatures as described herein.

FIG. 3A shows multiple coplanar component spacer blocks 300 a, 300 bforming a spacer block 301. Coplanar component spacer blocks 300 a, 300b can be part of a parallel vehicle panel system, such as for compositepanels. The component spacer blocks 300 a 300 b, may be coplanar orsubstantially coplanar (i.e. there may be some overlap between thespacers). The multiple component spacer blocks 300 a, 300 b may becoplanar on the same side of the exterior panel. The figure shows twocoplanar spacers, although more than two may be configured. Thecomponent blocks may be configured so that the corrugated lateral sides105 of the different spacer blocks 300 intersect at an angle 310. Theangle can be 0 to 180 degrees. In other embodiments, the componentspacers are not coplanar, and the angle between them may define a skewbetween the component spacer blocks. One or more component spacer blocksmay work collectively to further enhance the strength or absorptionqualities by a factor of n. For example, two or more component spacerblocks may have angles between corrugated portions which are (at leastpartially) in a honeycomb pattern. Two or more component spacer blocksmay be positioned adjacent one another to double the load absorption(e.g., for side vehicle impact zones.) As used herein, a honeycombpattern can be the two or more spacer blocks forming at least twoadjacent sides of a hexagonal shape (e.g. with 120 degrees). The sidesof that honeycomb pattern can be formed by the corrugated lateral sidesand/or non-corrugated lateral sides.

Because the (component) spacer blocks can be fastened to the exteriorpanel in select areas, and because of the configuration of the verticalsides of the component spacer blocks (e.g. the corrugated portion), thestrength and elasticity provided by the component spacer block(s) actsas an adhesive to seam the external panel together even in the event afracture does occur. For example, the portion of the external panelcoupled to a first component spacer block, can otherwise stay connected,or seamed with the portion of the exterior panel which is directlycoupled to a second component spacer block (the second component spacerblock other than the first component spacer block).

FIG. 4A shows a top plan view honeycomb pattern 400 for component spacerblocks. Component spacer blocks can be of the same configuration. Thecomponent spacer blocks may be coplanar, and the corrugated portions ofthe component spacer blocks may form cells 404 of the honeycomb pattern.It can be understood that the honeycomb pattern 400 can be applied onside of an exterior panel as described herein, for benefits as describedherein such as providing improved strength in a direction perpendicularto a surface of the exterior panel, and improved flexibility, ductilityalong another axis.

FIG. 4B shows another top plan view of another honeycomb pattern 415 ofcomponent spacer blocks. In some honeycomb configurations, sub-componentspacer blocks having corrugated lateral sides can form a largercomponent spacer block in the form of a honeycomb cell (e.g.substantially hexagonal in shape). For example, in FIG. 4B, a componentspacer block can include multiple lateral sides with each lateral sidehaving a corrugated configuration of a first type 420. These multiplelateral sides, each having a corrugated configuration, can form ahexagonal (or other shaped) shell. This can prevent any lateral forcesacting on an exterior panel from cracking and opening a large gap in theexterior panel, which would normally occur in the absence of the spacerblock (for example, if the exterior panel were made of resin). Further,a second type 425 of honeycomb cells can be formed with the componentspacer blocks having at least one, substantially straight lateral side405 f. Honeycomb cells can have portions which belong to one or morecomponent spacer blocks, and portions of component spacer blocks canbelong to one or more honeycomb cells. In other configurations, sides ofeach cell of the honeycomb pattern are non-corrugated, while other sidesare corrugated. In some configurations, sides of cells of the honeycombpattern facing a first direction are corrugated, while sides of cells ofthe honeycomb pattern along a different direction (other than the firstdirection) are non-corrugated. Although a first type 420 and a secondtype of honeycomb cells are shows here, honeycomb configurations havinga single type, or any combination of either of the types 420, 425, maybe configured. Further, other types of honeycomb patterns may beconfigured, including 3d honeycomb patterns using non-coplanar componentspacer blocks.

Spacer block reinforced resin panels described herein may thus offerdifferent levels of flexibility, ductility, and/or rigidity alongdifferent axes. Spacer blocks as described herein may be formed byadditive and/or subtractive manufacturing processes, and conventionaljoining and metallurgic methods. Spacer blocks as described herein canbe tested for and designed for specific parameters (e.g. rigidity,elasticity, ductility, frangibility) at or for specific criteria (suchas impact forces, impact directions, temperatures), and fall within thescope of the present disclosure.

Spacer block(s) of the present disclosure can facilitate design ofversatile composite panel systems with ease of manufacturability bycombining parallel and/or series spacer blocks. Knowledge of specificparameters of single spacer blocks (e.g. stiffness, flexibility,elasticity, strength) across different dimensions, may allow for meetingdesign requirements of vehicle systems (e.g. crash loads), whilepreventing damage deformations of exterior vehicle panels.

The term “coupled” refers to direct or indirect joining, connecting,fastening, contacting or linking, and may refer to various forms ofcoupling such as physical, mechanical, chemical, magnetic,electromagnetic, or other coupling, or a combination of the foregoing.Where one form of coupling is specified, this does not imply that otherforms of coupling are excluded.

Although illustrated and described above with reference to certainspecific embodiments and examples, embodiments of the present disclosureare nevertheless not intended to be limited to the details shown.Rather, various modifications may be made in the details within thescope and range of equivalents of the claims and without departing fromthe spirit of the present disclosure. It is expressly intended, forexample, that all ranges broadly recited in this document include withintheir scope all narrower ranges which fall within the broader ranges. Inaddition, features of one embodiment may be incorporated into anotherembodiment. Further, single continuous components shown, can becomprised of multiple subcomponents.

What is claimed is:
 1. A spacer for vehicle paneling, comprising: a topportion comprising an exterior panel coupling surface, the exteriorpanel coupling surface configured to couple to an exterior panel of avehicle; a shaped member extending from the top portion to a bottomportion, the shaped member comprising a channel extending through thespacer from the exterior panel coupling surface; wherein the shapedmember at least partially circumscribes a vertical aperture extendingthrough the shaped member from the exterior panel coupling surface tothe bottom portion.
 2. The spacer for vehicle paneling of claim 1,wherein the shaped member is configured to absorb a substantial portionof a first load applied in a first direction perpendicular to thecoupling surface; and wherein the channel is configured to allow acontrolled deformation when the first or a second load is appliedsubstantially along a direction along a width of the channel.
 3. Thespacer for vehicle paneling of claim 2, wherein the spacer is made ofdurable resin having a higher tensile strength in the first directionthan the direction along the width of the channel.
 4. The spacer forvehicle paneling of claim 1, wherein the spacer for vehicle paneling isconfigured for insertion in a body of a vehicle.
 5. The spacer forvehicle paneling of claim 1, wherein the channel has a vertex closer toa geometric center of the spacer than a geometric exterior of thespacer.
 6. The spacer for vehicle paneling of claim 1, wherein thechannel extends through the entire shaped member.
 7. The spacer forvehicle paneling of claim 1, further comprising a tether coupled to theshaped member on a first side of the channel, and at another point ofthe shaped member of a side of the channel other than the first side. 8.A composite panel system, comprising: an exterior panel; a first spacerpositioned proximal to the exterior panel, and shaped such that thefirst spacer is configured to: absorb a portion of a first load, thefirst load applied in a first direction substantially perpendicular tothe exterior panel; controllably deform along a second direction when asecond load is applied substantially along the second direction; whereinthe second direction is other than the first direction, and the firstspacer does not deform along the second direction when the first load isapplied.
 9. The composite panel system of claim 8, wherein the firstspacer comprises: a shaped member comprising one or more channels, theone or more channels extending substantially perpendicular to theexterior panel, from the exterior panel and at least partially thoughthe first spacer.
 10. The composite panel system of claim 9, wherein theone or more channel is configured to allow a controlled deformation whenthe first load is applied substantially along the second direction. 11.The composite panel system of claim 9, further comprising: a secondspacer positioned on the same side of the exterior panel as the firstspacer; wherein the second spacer further comprises: a second spacershaped member, the second spacer shaped member further comprising one ormore channels, the one or more channels extending from the exteriorpanel at least partially though to the second spacer.
 12. The compositepanel system of claim 11, wherein the first spacer and the second spacerare arranged in a honeycomb pattern such that the first spacer shapedmember and the second spacer shaped member couple at an angle.
 13. Thecomposite panel system of claim 12, wherein the angle is 120 degrees.14. The composite panel system of claim 9, the composite panel furthercomprising: a tether coupled to the shaped member and one other point ofthe first spacer.
 15. The composite panel system of claim 9, wherein theshaped member is configured to expand upon an impact.
 16. The compositepanel system of claim 8, further comprising: an inner panel on the otherside of the first spacer than the exterior panel, wherein the firstspacer is fastened to the inner panel and to the exterior panel.
 17. Thecomposite panel system of claim 8, wherein the first spacer is fastenedto the exterior panel such that in the event of a fracture at theexterior panel, the exterior panel remains seamed together.
 18. Thecomposite panel system of claim 8, further comprising: a shaped membercomprising a living hinge, the shaped member configured to controllablydeform along the second direction by the living hinge.
 19. The compositepanel system of claim 8, wherein the first spacer is made of durableresin having a higher tensile strength in the first direction than inthe second direction.
 20. The composite panel system of claim 8, whereinthe composite panel system is configured for insertion in a vehicle,such that the exterior panel is configured as a portion of a body of thevehicle.